Flexible packaging structure with built-in tamper-evidence features and method for making same

Abstract

A flexible packaging laminate formed by an outer structure joined to an inner structure. Score lines are formed in both structures to form a flap that is lifted to open the package. The score line through the outer structure defines a larger opening than the score line through the inner structure, such that a marginal region of the outer structure extends beyond the edge of the opening portion of the inner structure. A pressure-sensitive adhesive is used to re-adhere the marginal region to an underlying surface of the inner structure adjacent the opening through the laminate. The outer score line includes at least one tab having one end integrally joined to an outer edge of the flap and an opposite end anchored to a portion of the outer structure spaced from the outer edge, the tab being torn through upon initial creation of the opening through the flexible packaging laminate.

What is claimed is: 
     
       1. A flexible packaging structure having built-in opening/reclose and tamper-evidence features, comprising:
 an outer structure adhesively joined in face-to-face relation to an inner structure, the outer structure comprising a first flexible material and the inner structure comprising a second flexible material; 
 an outer line of weakness formed in the outer structure, the outer line of weakness defining an outer opening portion that is separable from the outer structure along the outer line of weakness; 
 an inner line of weakness formed in the inner structure, the inner line of weakness defining an inner opening portion that is separable from the inner structure along the inner line of weakness; 
 wherein the inner opening portion is joined to the outer opening portion such that lifting the outer opening portion out of the plane of the flexible packaging structure causes the inner opening portion to be lifted along with the outer opening portion so as to create an opening through the flexible packaging structure; 
 wherein a marginal region of the outer opening portion is defined between the inner and outer lines of weakness, the marginal region overlying an underlying surface of the inner structure; 
 wherein a pressure-sensitive adhesive is disposed on one of an overlying surface of the outer opening portion and the underlying surface of the inner structure for re-adhering the overlying surface to the underlying surface after opening; and 
 a tamper-evidence feature that is initially in an untorn condition prior to initial creation of the opening, and whose untorn condition is apparent from a visual inspection of the outer structure, wherein the tamper-evidence feature comprises a first tab having one end integrally joined to an outer edge of the marginal region and an opposite end anchored to a portion of the outer structure spaced from the outer edge, the first tab being torn through upon initial creation of the opening through the flexible packaging structure. 
 
     
     
       2. The flexible packaging structure of  claim 1 , wherein the first tab further comprises an indentation. 
     
     
       3. The flexible packaging structure of  claim 1 , wherein the first tab further comprises a prong extending from a side of the first tab. 
     
     
       4. The flexible packaging structure of  claim 1 , wherein the first tab is free from pressure-sensitive adhesive or lamination to the inner structure. 
     
     
       5. The flexible packaging structure of  claim 1 , wherein the tamper-evidence feature further comprises a second tab spaced from the first tab, the second tab having one end integrally joined to the outer edge of the marginal region and an opposite end anchored to a portion of the outer structure spaced from the outer edge. 
     
     
       6. The flexible packaging structure of  claim 1 , wherein the second tab is free from pressure-sensitive adhesive or lamination to the inner structure. 
     
     
       7. The flexible packaging structure of  claim 1  in combination with a container body having a side wall and a flange extending from an upper edge of the side wall, wherein the flexible packaging structure comprises a lid, the lid being attached to the flange to seal closed the package. 
     
     
       8. A flexible packaging structure, comprising:
 a flexible packaging laminate comprising an outer structure adhesively laminated to an inner structure; 
 an opening and reclose feature formed in the laminate, and comprising an outer flap portion formed by scoring through the outer structure along an outer score line, and an inner flap portion formed by scoring through the inner structure along an inner score line, the inner score line creating an opening into the container when the flap portions are peeled back in a first direction, a marginal region of the outer flap portion extending beyond an edge of the inner flap portion and overlying an underlying surface of the inner structure, both portions being peeled back as a unit upon opening of the container; and 
 a tamper-evidence feature that is initially in an untorn condition prior to initial creation of the opening, and whose untorn condition is apparent from a visual inspection of the outer structure, wherein the tamper-evidence feature comprises a first tab having one end integrally joined to an outer edge of the marginal region and an opposite end anchored to a portion of the outer structure spaced from the outer edge, the first tab being torn through upon initial creation of the opening through the flexible packaging structure. 
 
     
     
       9. A method for making a flexible packaging laminate having built-in opening/reclose and tamper-evidence features, comprising the steps of:
 applying a pressure-sensitive adhesive onto one surface of a first structure comprising at least one layer of flexible material; 
 adhesively joining the first structure to a second structure so as to form a laminate, the second structure comprising at least one layer of flexible material, wherein one of the first and second structures comprises an outer structure and the other comprises an inner structure; 
 advancing the laminate to a scoring station at which an outer score line is formed through the thickness of the outer structure and an inner score line is formed through the thickness of the inner structure in registration with the outer score line, the outer score line delineating an outer opening portion of the outer structure that is separable from the outer structure along the outer score line, the inner score line delineating an inner opening portion of the inner structure that is affixed to the outer opening portion and is separable from the inner structure along the inner score line, wherein a region of the outer opening portion between the outer and inner score lines is attached to an underlying surface of the inner structure via the pressure-sensitive adhesive, the outer opening portion being peelable from the underlying surface of the inner structure so as to cause the inner opening portion to also be peeled back to create an opening in the laminate, and the outer opening portion being re-attachable to the underlying surface of the inner structure via the pressure-sensitive adhesive for reclosing the opening; and 
 forming a tamper-evidence feature in the outer structure that is initially in an untorn condition prior to initial creation of the opening, and whose untorn condition is apparent from a visual inspection of the first structure, wherein the step of forming the tamper-evidence feature comprises forming a first tab having one end integrally joined to an outer edge of the outer opening portion and an opposite end anchored to a portion of the outer structure spaced from the outer edge, the first tab being torn through upon initial creation of the opening through the flexible packaging laminate. 
 
     
     
       10. The method of  claim 9 , wherein the first tab is formed to have an indentation. 
     
     
       11. The method of  claim 9 , wherein the first tab is formed to have a prong extending from a side of the first tab. 
     
     
       12. The method of  claim 9 , wherein the step of forming the tamper-evidence feature further comprises forming a second tab spaced from the first tab, the second tab having one end integrally joined to the outer edge of the outer opening portion and an opposite end anchored to a portion of the outer structure spaced from the outer edge.